Expansible corrugated paperboard carton



Aug. 18, 1964 F. L. YOUNG 9 EXPANSIBLE CORRUGATED PAPERBOARD CARTONFiled Aug. 5, 1965 INVENTOR.

FRANK L. YOUNG Mzwu;

ATTORNEYS United States Patent 3,144,979 EXPANSIELE CORRUGATEDPAPERBOARD CARTON Frank L. Young, 1601 N. 72nd St., Philadelphia, Pa.Filed Aug. 5, 1963, Ser. No. 299,812 2 (Ilaims. (Cl. 229-41) Thisinvention relates to an expansible corrugated paperboard carton which isadapted to be fabricated from a single blank on continuous folding andgumming machines. More particularly, it relates to a flatly formedcarton having folding lateral panels which are capable of being readilyexpanded or contracted to accommodate articles of various sizes whileproviding protection to fragile contents against shock or other damageat all times. The carton of the instant invention is especially suitablefor shipping, mailing or storage of merchandise such as books, bottlesand the like, and is easily convertible from a flat envelopeconfiguration to a sturdy box-like container which will resilientlyprotect the en closed article.

In the past, collapsible cartons were designed only to hold the contentswhen the container was fully erected in the form of a box. While thecartons themselves could be shipped or stored in flat or knock-downcondition, they were not capable in their folded state of receivingarticles. That is, their construction was primarily intended foremployment as a completely assembled shipping container, and they werenot adapted in collapsed condition for use as a shipping medium.

Furthermore, the prior art cartons of a particular cubic dimension couldnot readily accommodate articles of various sizes and shapes. Wherearticles of much smaller dimension than that of the carton itself werepacked, stutfing with dunnage was required in order to prevent unduefreedom of movement and rattling in transit.

It is therefore an object of this invention to provide a collapsiblecarton which has equal utility as a container in either fiat-folded,partially expanded, or fully expanded condition.

Another object of this invention is to provide a corrugated paperboardcontainer which is capable of being stored flat and thereafter used as aflat-folded envelope or which can be expanded into box-likeconfiguration to receive articles of various sizes.

It is also an object of the invention to provide a container whereinirregularly shaped objects, not completely filling the container, may bewedged into fixed position by a bottom element, when said element ispartially expanded.

Another object of this invention is to provide a corrugated paperboardenvelope having expansible lateral panels which is adapted to offerprotection against shock or other damage to fragile articles receivedtherein.

An additional object of the invention is to provide an envelope havingdouble edges on each side which afford additional protection for thecontents when the envelope is partially expanded.

Another object of this invention is to provide an expansible corrugatedpaperboard carton which will resiliently embrace articles of varioussizes and shapes so that articles having dimensions much smaller thanthe expanded carton can be retained in generally fixed position thereinduring shipment without requiring dunnage or stuffing.

Still another object of this invention is to provide an envelope-like,expansible, corrugated-paperboard carton which can be readily fabricatedon continuous gumming and folding machines.

Yet another object of this invention is to provide a corrugatedpaperboard container which is urged into expanded condition as thearticles are inserted therein.

3,144,979 Patented Aug. 18, 1964 A still further object of thisinvention is to provide an expansible envelope fabricated fromcorrugated paperboard and having fully closed upper and lower corners.

Other objects of this invention are to provide an improved device of thecharacter described that is easily and economically produced, which issturdy in construction, and which is highly efficient and eifective inoperation.

With the above and related objects in View, this invention consists ofthe details of construction and combination of parts as will be morefully understood from the following detailed description when read inconjunction with the accompanying drawing, in which:

FIGURE 1 is a plan view of a corrugated paperboard blank from which anexpansible carton embodying this invention is formed.

FIGURE 2 is a perspective view of the blank in partly folded positionwith marginal edges of the. side flaps in overlying sealed relationshipso as to form the front panel of the carton.

FIGURE 3 is a fragmentary perspective view of the bottom portion of theexpansible carton with the bottom flap sealed in overlying relationshipwith. the lower portion of the front panel.

FIGURE 4 is a perspective View of the carton in fully expanded positionwith the top flap open preparatory to sealing thereof.

FIGURE 5 is a fragmentary perspective view of the lower portion of theexpanded carton taken generally along lines 5-5 of FIGURE 4.

Referring now in greater detail to the drawingin which similar referencecharacters refer to similar parts, I show a corrugated paperboard singleblank, in FIGURE 1, which is so shaped and scored as to provide, whenfolded and adhesively secured, an expansible gusset carton thatresembles an envelope in fiat condition but which is adapted to beexpandedly formed into a box-like configuration. The blank is preferablyfabricated from singlefaced, corrugated paperboard of a special design,generally classified in the trade as B-fluting. The blank configurationcomprises a generally rectangular central panel 10 having a pair ofinwardly folding lateral panel sections 12 outwardly extending therefromalong longitudinal scores 13. A second pair of folding panel sections14- are secured to the first panel sections along intermediate foldlines 15. Extending outwardly from the i second folding panel sectionson longitudinal scores 17 are respective wing sections 16 and 18 whichare adapted to overlap at their marginal edges when the blank is foldedinwardly, outwardly, and then inwardly along the triple score lines 13,15, and 17. A paste or gum is applied to the portion 19 so that when theoverlapped edges of the wing sections 16 and 18 are pressed togetherthey are adhesively secured and form a center seam front panel 20 whichoverlies the central or back panel 10.

A top closure 30 upwardly extends from the central panel 10 alongtransverse scores 21 and includes a sealing flap 32 together withintermediate sections 34 and 36 disposed between transverse creases 33and 35. Hinged to the lower edge of the central panel 10 is a bottompanel 46 which includes a pair of foldable panel sections 42 and 44 aswell as a sealing flap 46. The bottom panel sections 42 and 44 and thesealing flap 46 are hinged together along triple transverse scores 45,47, and 49.

Downwardly depending from the lateral panel sections 12 and 14 andcontained intermediate continuations of the transverse scores 45 and 47are a pair of gusset portions 50 and 52. These gusset portions 50 and 52have respective diagonal scores 51 and 53 along which these portions areadapted to break to form triangular corner gussets during expansion ofthe carton. A sealing tab 58 depends from each gusset portion 50 alongscore line 47 and is hinged to the lateral edges of bottom panel section44 along extensions of the longitudinal scores 13.

Upper corner closures are defined by corner flaps 62 and 64 whichupwardly extend from the respective lateral panel sections 12 and 14along score line 21, both corner flaps terminating along a lineregistering with transverse score 33 and being hinged to each otheralong continuations of longitudinal scores 15. The corner flap portions62 are split or spaced from the top panel sections 34 and 36 alongextensions of the longitudinal scores 13. A transverse score 65registering with score 35 divides the flaps 62 and 64 into sectionsalong which the corner closures may break when the carton is partiallyexpanded.

The blank is formed into the expansible carton by folding the wingportions inwardly, outwardly and inwardly along the longitudinal scores13, 15, and 17 so as to bring the lateral panel sections 12 and 14 intointeriorly folded overlying disposition. The wings 16 and 18 areoverlapped at their marginal edges and secured by adhesive at 19 so asto define a front panel 20 with a center seam. This initial foldingoperation causes the gusset portions 50 and 52 to be into face to facecontact with each other while the sealing tabs 58 overlie the outboardareas of the bottom panel section 44. Similarly, the corner flaps 62 and64 are urged into facing contact. FIGURE 2 is generally illustrative ofthe preliminary configuration of the carton after the first steps, asset forth above, have been completed. It is also to be observed that theouter marginal edge of the corrugated face of the wing 16 may be adheredto the abutting, smooth-back face of the wing 18.

The corrugated flutes on both the top sealing flap 32 and the bottomsealing flap 46 are pressed flat by passing them through steel rollers,for example. Similarly, the corrugated face of each gusset portion 52 ispressed flat so that better adhesive attachment will be provided whenthese surfaces are glued to the respective faces which they will abut.In addition, the fold line 47 is re-scored preparatory to the bottomflap fold-over and seal.

Glue is now applied to the flattened corrugated face of the bottom flap46 and also to the now upwardly facing smooth surface of the sealing tab58. If desired, the corrugated surface of the now upwardly facing gussetportions 52 may have adhesive applied thereto additionally. Lastly, apressure sensitive adhesive is applied to the flattened corrugatedsurface of the top sealing flap 32 and also to the upper margin of thesmooth, now outwardly facing surface of the front panel 20.

The bottom panel 40 is now folded outwardly along the intermediate scoreline 47 so that the corrugated face of the bottom sealing flap 46 isadhesively secured into face-to-face contact with the lower margin ofthe front panel 20. The smooth surface of the sealing tabs 58 willaccordingly be pressed against and sealed in contact with the corrugatedface of the corresponding gusset portions 52. As is apparent, the bottomcorners of the carton are now fully closed and sealed, substantially asshown in FIGURE 3.

When the flat envelope, shown in FIGURE 3, is to be expanded to form theboxlike container of FIGURE 4, the front panel 20 is moved outwardlyaway from the back panel 10. The panel sections 12 and 14 hingeoutwardly along the lines of fold 13, 15, and 17 respectively and formside walls 70 and 8t Simultaneously the transverse scores 45 and 49break into folds while the bottom panel sections 42 and 44 are urgedinto a common plane to define the bottom wall 40, as shown in FIGURES 4and 5. During this expansion, the gusset portions 50 and 52 break alongthe diagonal folds 51 and 53 so that a triangular gusset is formed whichlies in a plane parallel to and in abutment with the bottom panel 40.The upper corner flaps 62 and 64 fold open in unison with the lateralpanel sections 12 and 14 and form common planes with the side walls 70and 80. However, when the top flap 30 is folded downwardly so that itssealing flap 32 abuts the front panel 20, the corner flaps 62 and 64 areflattened along the fold line line 21 so as to underlie the top panel30. These corner flaps not only protect the contents of the container atits upper lateral edges but also serve to reinforce the top cornersthereof against crushing. In a similar manner, the triangular gussets5i) and 52 reinforce the bottom corners of said carton. When the cartonis shipped as a flat envelope, the corner flaps 62 and 64 may be foldedalong the intermediate score 65. This will also allow perfectregistration of the pressure sensitive glue on flap 32 and upper portionof front panel 20.

The corrugated paperboard used in the fabrication of the cartonhereindescribed serves to isolate fragile articles contained thereinagainst shock, vibration and atmospheric conditions. The carton itselfis easily formed on conventional continuous gumming and foldingmachines. In view of the nature of the resiliently expansible panels,the carton tends to maintain itself in collapsed position. Thus, whenthe contents are not suflicient to fully expand the carton into boxlikeconfiguration, the various panels tend to resiliently bear upon thecontained articles and retain them in a generally stable positiontherein. Many different articles including books, papers, and evenglassware, such as bottles and dishes, can be conventiently handled bythe above expansible carton. A single carton size can efficientlyaccommodate objects of various shapes and cubic dimensions. It istherefore obvious that the instant carton can be employed as a flatprotective envelope, as a boxlike shipping container, or even as anintermediate collapsible container which would space adjacent articlesin a case from each other.

Although this invention has been described in considerable detail, suchdescription is intended as being illustrative rather then limiting sincethe invention may be variously embodied, and the scope of the inventionis to be determined as claimed.

What is claimed is:

1. A gusset carton adapted to be expanded from an initially flat-foldedcontainer into a rectangular container of boxlike configurationcomprising; a one-piece blank of single-faced corrugated paperboardincluding substantially rectangular front and back panels overlying eachother, side walls hinged to the respective outboard edges of said frontand back panels along pairs of longitudinal folds, each of said sidewalls having a longitudinal reverse fold intermediate each pair oflongitudinal folds to form inwardly-folded lateral panel sectionsoverlying each other between said front and back panels, a bottom hingedto the lower edges of said front and back panels along a pair oftransverse folds and having an intermediate transverse fold therebetweento form outwardlyfolded bottom panel sections overlying each other, saidfront panel including wings with sealed overlapping marginal edges atthe central portion thereof, said bottom including a bottom seal flaphaving flattened corrugated flutes adhesively secured to the lowermarginal edge of said front panel, diagonally-scored gusset portionsdownwardly depending from the respective lateral panel sections alongcontinuations of the transverse fold connecting said bottom with saidback panel and terminating along a line registering with the transversefold intermediate said bottom panel sections, adjacent gusset portionsbeing hinged to each other and the gusset portions next adjacent thebottom panel section which is hinged to said back panel being hinged tosaid last-mentioned bottom panel section, sealing tabs depending fromthe lastrnentioned gusset portions along the intermediate transversefold and being further hinged to the bottom panel section which ishinged to said front panel, said sealing tabs being adhesively securedin face-to-face abutment with the gusset portions which are connected tothe lateral panel sections hinged to said front panel, said gussetportions being substantially co-planar with the respectiveinwardly-folded lateral panel sections when the carton is in flattenedcondition, said gusset portions breaking along their respective diagonallines of fold and forming triangular sections overlying the flat bottomin parallel planes therewith when the carton is squared out into boxlikeconfiguration, a top closure flap connected to the upper edge of saidback panel and transversely triple scored so as to be divided into a topsealing flap adapted to be adhesively secured to said front panel and apair of hinged-top panel sections which are adapted to form asquared-off top panel, and a corner flap hinged to the upper edge ofeach of said lateral panel sections and terminating at the transversescore intermediate said top sealing flap and the next adjacent top panelsection, adjacent corner flaps being hinged together along continuationsof the intermediate longitudinal folds.

2. A flatly-folded carton fabricated from a single blank of corrugatedpaperboard and adapted to be formed after being folded and sealed into afully expansible gussettype container, comprising substantiallyrectangular front and back panels overlying each other, side wallshinged to the respective edges of said front and back panels along pairsof longitudinal folds, each of said side Walls having an intermediatelongitudinal reverse fold with respect to each pair of longitudinalfolds to form inwardly folded lateral panel sections overlying eachother between said front and back panels, a bottom connected along oneedge to the lower edge of said back panel by a transverse fold andhaving a Width corresponding to the width of the side Walls and havingan intermediate fold to provide bottom panel sections overlying eachother, said front panel including wings with sealed overlapping marginaledges at the central portion thereof, a bottom seal flap connected withthe opposite edge of said bottom along a transverse fold and adhesivelysecured in overlapping relationship with the lower marginal edge of saidfront panel, diagonally-scored gusset portions downwardly depending fromthe respective lateral panel sections along continuations of saidfirstmentioned transverse fold and terminating along a line registeringwith the intermediate fold of said bottom, said gusset portions beingadjacently hinged to each other and to the bottom along the respectivelongitudinal folds, sealing tabs depending from the gusset portionswhich are hinged to the lateral panel sections immediately adjacent theback panel along the intermediate transverse fold and being furtherhinged to the bottom panel section along a continuation of thelongitudinal fold at the edge of said back panel, said sealing tabsbeing adhesively secured in face-to-face abutment with the gussetportions which are hinged respectively to the lateral panels connectedto said front panel, said gusset portions being substantially co-planarwith the respective inwardly-folded lateral panel sections when thecarton is in collapsed condition, said gusset portions breaking alongtheir respective diagonal lines of fold and forming triangular sectionsoverlying the flat bottom in parallel planes therewith when the cartonis squared out into boxlike configuration, and a top closure flapconnected to the upper edge of said back panel and transverselytriplescored so as to be divided into a top sealing flap adapted to besecured to said front panel and a pair of hingedtop panel sections whichare adapted to form a squaredoif top panel.

References Cited in the file of this patent UNITED STATES PATENTS916,544 Ferres Mar. 30, 1909 1,461,967 Butterfield July 17, 19232,271,962 Weiner Feb. 3, 1942 2,411,144 Bcrgstein Nov. 19, 19462,517,756 Zabriskie et al. Aug. 8, 1950 2,551,090 Bergstein May 1, 19512,580,180 Meller Dec. 25, 1951 2,988,261 Keating June 13, 1961

1. A GUSSET CARTON ADAPTED TO BE EXPANDED FROM AN INITIALLY FLAT-FOLDEDCONTAINER INTO A RECTANGULAR CONTAINER OF BOXLIKE CONFIGURATIONCOMPRISING; A ONE-PIECE BLANK OF SINGLE-FACED CORRUGATED PAPERBOARDINCLUDING SUBSTANTIALLY RECTANGULAR FRONT AND BACK PANELS OVERLYING EACHOTHER, SIDE WALLS HINGED TO THE RESPECTIVE OUTBOARD EDGES OF SAID FRONTAND BACK PANELS ALONG PAIRS OF LONGITUDINAL FOLDS, EACH OF SAID SIDEWALLS HAVING A LONGITUDINAL REVERSE FOLD INTERMEDIATE EACH PAIR OFLONGITUDINAL FOLDS TO FORM INWARDLY-FOLDED LATERAL PANEL SECTIONSOVERLYING EACH OTHER BETWEEN SAID FRONT AND BACK PANELS, A BOTTOM HINGEDTO THE LOWER EDGES OF SAID FRONT AND BACK PANELS ALONG A PAIR OFTRANSVERSE FOLDS AND HAVING AN INTERMEDIATE TRANSVERSE FOLD THEREBETWEENTO FORM OUTWARDLYFOLDED BOTTOM PANEL SECTIONS OVERLYING EACH OTHER, SAIDFRONT PANEL INCLUDING WINGS WITH SEALED OVERLAPPING MARGINAL EDGES ATTHE CENTRAL PORTION THEREOF, SAID BOTTOM INCLUDING A BOTTOM SEAL FLAPHAVING FLATTENED CORRUGATED FLUTES ADHESIVELY SECURED TO THE LOWERMARGINAL EDGE OF SAID FRONT PANEL, DIAGONALLY-SCORED GUSSET PORTIONSDOWNWARDLY DEPENDING FROM THE RESPECTIVE LATERAL PANEL SECTIONS ALONGCONTINUATIONS OF THE TRANSVERSE FOLD CONNECTING SAID BOTTOM WITH SAIDBACK PANEL AND TERMINATING ALONG A LINE REGISTERING WITH THE TRANSVERSEFOLD INTERMEDIATE SAID BOTTOM PANEL SECTIONS, ADJACENT GUSSET PORTIONSBEING HINGED TO EACH OTHER AND THE GUSSET PORTIONS NEXT ADJACENT THEBOTTOM PANEL SECTION WHICH IS HINGED